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Design and Analysis of Formula ISSN XXXX XXXX © 2019 IJESC Research Article Volume 9 Issue No.3 Design and Analysis of Formula - 3 Frame R.Vasanthakumar1, P.R.Manojkumar2, M.Kesavaraj3, G.Manikandan4 Assistant Professor1, Final Year UG Student2, 3, 4 Department of Mechanical Engineering KSR Institute for Engineering and Technology, Namakkal,Tamilnadu, India Abstract The design of race car for the beginner cart competition involves more performance parameters then for regular racing. In addition to achieving high strength and stiffness for a very low overall weight, the car must be easily manufacturable and maintainable to stay within budget. In this an approach is presented on designing a lightweight hybrid race car chassis consisting of a fiber reinforced composite cockpit combining structural, esthetic, ergonomic and crash properties, and a tubular space frame engine compartment, meeting stiffness and strength demands while remaining easy to maintain and manufacture, thus keeping production cost low. Beginner cart is a small racing car, based on construction of the Formula Three. Due to security issues, there is a number of regulations that must be respected in the construction and design of this Formula vehicle. The frame is designed in the “PTC Creo 4.0" software, in which the structural analysis of the load using the finite element method is performed. Based on facted analysis, optimal conception of frame is suggested. Keywords: beginner cart, chassis frame, design, FEA. 1. INTRODUCTION without body is called Chassis. The chassis must be rigid in both torsion and bending and must be able to resist twisting and Formula Three, also called Formula 3 or F3, is a class sagging. The chassis must be able to accommodate and support of open-wheel formula racing. The chassis frame has been used all the components of the vehicle and any occupants and must widely in varsity level formula race car. Due to its advantage absorb all loads without excessive deflection. of easy to be manufactured and easy to be repaired, space frame chassis is the most favourable choice for race car TYPE OF CHASSIS DESIGN development of newly introduced varsity level of beginner cart competition.The chassis of an automobile is defined as frame Ladder frame chassis supported on springs and attached to the axle that holds the The ladder frame chassis was the earliest type of body and engine of vehicle. Chassis is a French word and was chassis used. It was widely used for the earliest cars until the initially used to denote the frame parts or basic structure of an early 60s. The design is, as the name suggest, similar to a automobile. ladder. There are two longitudinal rails running the length of the The conventional construction, in which a separate vehicle which are connected together by several lateral and frame is used and the frameless or unitary construction in cross braces. which no separate frame is employed. Out of these, the conventional type of construction is being used presently only Space frame chassis for the heavy vehicles. While for the car same has been The space frame was the next logical step up from the replaced by the frameless type or the monocoque chassis. The ladder frame. A space frame has a number of features that purpose is to design and manufacture tubular space frame distinguish it from a ladder frame and add massive advantages. chassis that should be strong enough to absorb the energy A perfectly designed space frame would have the tubular when front, back, side, torsional loads are applied. sections arrange so that the only forces on them are either In this project summarizes the design, fabrication and tension or compression analysis processes of the chassis frame. The end product is then used in actual assembly of the race car together with the Monocoque chassis other components. Due to some tolerances in fitting and The Monocoque style of chassis is used by almost all welding processes, the final chassis frame is modified and car manufacturers today. A Monocoque is a one-piece structure changed slightly throughout the fabrication process. The frame that defines the overall shape of the vehicle. This type of chassis is designed in the PTC Creo 5.0 software. Ergonomics is also is very attractive to mass production as the process can be consideredas one of the most important design aspect. Analysis automated very easily. The structure also has very good crash of the final CAD model is done on ANSYS WORKBENCH protection as crumple zones can be built into the structure itself. 17.0. Different load cases are considered during finite element analysis to ensure that the chassis can endure the forces acting Backbone chassis during the vehicles motion. A backbone chassis is a simple style of frame that uses a central backbone running the length of the chassis that 2. THE CHASSIS connects to the front and rear suspension attachment areas. The backbone usually has a rectangular cross section. The body of The chassis is possibly the most important part of any the vehicle is then placed onto of the structure. This type of vehicle. Its main role is to provide the vehicle with a main chassis is used sometimes for small sports cars however it structure which all other components can be fixed to a vehicle International Journal of Engineering Science and Computing, March 2019 20840 http://ijesc.org/ provides little or no protection against a side impact and so 5. CAD MODEL requires the body to be designed to accommodate this. Modelling was done by using PTC Creo 5.0 software. 3. MATERIAL SELECTION Here the model is considered as surface body and thickness for the surface is considered as 3mm. the force that has been The selection of the material gave prime emphasis of imposed downward to the structural model. The load is being light weight and highly rigid and durable .AISI 4130 distributed uniformly and equally on the members below the alloy chromium molybdenum (CrMo) steel is high strength driver’s seat and engine compartment. material with very less weight. It is used in manufacturing of air craft and its cost is high based on the survey the Table 1 has the properties of various materials and the materials AISI 1018 was chosen for the chassis. This material has been selected by the following factors cost, availability, strength, machinability and durability. SI. Material Material NO properties AISI AISI AISI 1018 1020 4130 1 Density (g/cc) 7.87 8.03 7.85 Figure 5.1 Orthogonal view Cost (Rupees) 450 490 680 2 Hardness (HB) Dimension of frame 3 126 111 217 Length 2.6375 m Ultimate Strength Width 0.935 m 4 (MPa) 440 394.7 560 Height 1.0774 m Yield Strength 5 (MPa) 370 294.8 460 Table 2: Final dimensions of frame 6 Machinability 60% 68% 70% The frame of vehicle is very important part, and, until design process of vehicles, it paid special attention, because it is Table 1: Properties of materials loaded with very high loads (static and dynamic). Projecting and manufacturing represent big challenge, because many factors 4. DESIGN METHODOLOGY affect on its final version. Space frame (which is the most used kind of frame in Formula student vehicles) represent very complex tubular truss construction, on which we can notice, Create a 2D sketch designs separate and define its main elements. 6. ANALYSIS The safety and the strength of the chassis are important Select optimized design issues for its structure to meet the requirements, in which the structural analysis of the frame using the finite element method performed. Based on the structural analysis, optimal conception of frame is suggested. 3D modelling using PTC Creo 5.0 Parameter Value Unit Material AISI 1018 Finite Element Analysis using ANSYS Kerb weight 250 Kg Mass 97.041 Kg Comparison with theoretical calculation Volume 1.233e-002 m3 Total length 2.6375 m Result Height 1.0774 m Width 0.935 m The methodology has been followed to the frame in 2 Creo and analysis it in the ANALSYS software. The theoretical Young’s modulus 2.e+011 N/m (or)Pa values are calculated and compared with actual values. Table 3: Frame Specification International Journal of Engineering Science and Computing, March 2019 20841 http://ijesc.org/ RESULT AND DISCUSSION The applied impact load is 7000 N Front impact analysis Type of Total Equivalent stress analysis deformation Maximum [Pa] 4.1507e-004 1.9768e+008 Factor of Safety 2.857 Rear impact analysis Fig 1: Total Deformation From the consideration of above tabled properties of the static structural impact analysis were done and generated results are summarized as below. Fig 5: Total Deformation Fig 2: Equivalent stress The applied impact load is 7500 N Type of analysis Total Equivalent stress deformation Maximum [Pa] 3.8544e-004 3.7108e+007 Factor of Safety 1.1859 Fig 6: Equivalent Stress Side impact analysis The applied impact load is 8000 N Type of Total Equivalent stress analysis deformation Maximum [Pa] 6.0555e-003 3.6086e+008 Factor of Safety 1.22 7. CONCLUSION After all the forces and boundary conditions were Fig 3: Total Deformation applied plots of stress and deflection were studied and conclusions were made about the design. This paper focuses on the design, analysis and calculation of various components that is necessary for fabrication of a formula 3 frame. We have performed various types of static analysis and applied different loading conditions on the frame and it if found to be safe according to their factor of safety. We also learn how to select appropriate material for the safe design of frame. Successful analysis was perform on the frame of CAD modal using ANSYS WORKBENCH to determine, equivalent stresses, and total deformation results.
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